Method for manufacturing a vibration actuator

ABSTRACT

A method for manufacturing a vibration actuator includes forming an elastic body integrally with a projection protruding from a surface of the elastic body, by press working. Forming the elastic body includes forming a bonding portion surrounding the projection, forming a contact portion at a top portion of the projection, forming a spring portion between the contact portion and the bonding portion, and forming a standing portion having a hollow structure, between the spring portion and the contact portion, so that the standing portion has a ring shape in a cross-sectional view in a direction parallel to the surface of the elastic member and that a space surrounded by the contact portion, the spring portion, and the standing portion. The spring portion is formed by press working, and the bonding portion is formed by press working.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a divisional of U.S. patent application Ser. No. 13/052,989 filed Mar. 21, 2011, which claims the benefit of Japanese Patent Application No. 2010-065587 filed Mar. 23, 2010, all of which are hereby incorporated by reference herein in their entirety.

BACKGROUND OF THE INVENTION

Field of the Invention

The present invention relates to vibration actuators and methods for manufacturing the vibration actuators. More particularly, the present invention relates to a vibration actuator including a substantially rectangular planar vibrator having a projection that serves as a friction member on one side thereof and a method for manufacturing the vibration actuator.

Description of the Related Art

Various vibration actuators that linearly drive driven members have been proposed. For example, U.S. Pat. No. 7,109,639 proposes a vibration-type driving apparatus. The driving principle of the apparatus will be described with reference to FIGS. 11, 12A, and 12B. Referring to FIG. 11, a vibrator 106 is provided with an electromechanical conversion device 107 bonded thereto. FIGS. 12A and 12B illustrate two bending vibration modes of the piezoelectric vibrator. The vibration mode illustrated in FIG. 12A is one of the two bending vibration modes (hereinafter called mode A). Mode A is the second-order bending mode in the long-side direction of the rectangular vibrator 106 (direction shown by arrow X), and has three nodes that are parallel to the short-side direction (direction shown by arrow Y). Projections 108 are located near the nodes of the mode A vibration, and reciprocate in the direction shown by arrow X in response to the mode A vibration. The vibration mode illustrated in FIG. 12B is the other one of the two bending vibration modes (hereinafter called mode B). Mode B is the first-order bending mode in the short-side direction of the rectangular vibrator 106 (direction shown by arrow Y), and has two nodes that are parallel to the long-side direction (direction shown by arrow X).

The nodes in mode A and the nodes in mode B are substantially orthogonal to each other in the XY plane. The projections 108 are located near the antinode of the mode B vibration, and reciprocate in the direction shown by arrow Z in response to the mode B vibration. An end portion of each projection 108 performs an ellipsoidal movement when the vibrations of mode A and mode B are generated at a predetermined phase difference. A slider 116, which serves as a driven member, is in pressure contact with the end portions of the projections 108, as shown in FIG. 11. The slider 116 can be moved in the direction shown by arrow L in response to the ellipsoidal movement of each projections 108.

In this ultrasonic motor, the driven member is brought into pressure contact with the vibrator that vibrates, so that the driven member moves relative to the vibrator in response to the vibration. Accordingly, there is a possibility that an abnormal noise will be generated as the driven member hops in response to the vibration of the vibrator. In addition, there is also a possibility that the stability of the relative movement will be reduced. To overcome these disadvantages, it is necessary to provide an elastic deformable portion that can effectively receive the vibration from the vibrator. For example, Japanese Patent Laid-Open No. 2006-174549 proposes a vibration wave driving apparatus in which spaces are provided in a surface at the side opposite to the projections, as illustrated in FIG. 13. Referring to FIG. 13, in this apparatus, a vibration actuator 207 includes a vibrator 206 and a slider 204, and the vibrator 206 includes an electromechanical conversion device 203, an elastic member 201, and projections 202 bonded to the elastic member 201. Spaces 205 are formed in a bonding surface of the elastic member 201 that is bonded to the electromechanical conversion device 203 at areas opposite to the bonding areas at which the projections 202 are bonded. The area of each space 205 is larger than the bonding area of each projection 202. Therefore, portions of the elastic member 201 at which the spaces 205 are formed function as diaphragms and are elastically deformed, thereby providing a function as springs.

In the above-described structure according to Japanese Patent Laid-Open No. 2006-174549, elastic deformable portions are provided for receiving the vibration from the vibrator. Accordingly, the abnormal noise can be somewhat reduced and the stability of the relative movement can be increased. However, this structure has the following problem. That is, since the projections are provided as separate components and are bonded to the planar elastic member, there is a risk that the projections will be slightly displaced. As a result, there is a possibility that the desired spring stiffness cannot be obtained or the desired performance cannot be achieved by the actuator. In addition, since the number of manufacturing steps is increased, high costs are incurred.

SUMMARY OF THE INVENTION

The present invention provides a vibration actuator which has a stable spring stiffness and which can be easily manufactured. The present invention also provides a method for manufacturing the vibration actuator.

According to an aspect of the present invention, a vibration actuator includes an elastic body on which at least one projection is formed; and a vibrating body including an electromechanical conversion device. The vibration actuator drives a driven member that is in contact with a contact portion of the projection by causing an end portion of the projection to perform an ellipsoidal movement in response to a combination of two vibration modes generated in the vibrating body when an alternating driving voltage is applied to the electromechanical conversion device. The elastic body is formed integrally with the projection and a bonding portion between the projection and the electromechanical conversion device. A space is provided between the contact portion and the electromechanical conversion device to which the projection is bonded. The projection includes a standing portion that connects the contact portion and a spring portion to each other. The spring portion has a smaller thickness than thicknesses of the contact portion, the standing portion, and the bonding portion between the projection and the electromechanical conversion device. The spring portion is provided between the bonding portion between the projection and the electromechanical conversion device and the contact portion, the spring portion causing the projection to exhibit a spring characteristic when the contact portion is pressed as a result of the contact with the driven member. Another aspect of the present invention provides a method for manufacturing a vibration actuator including an elastic body on which at least one projection is formed and a vibrating body including an electromechanical conversion device, the vibration actuator driving a driven member that is in contact with a contact portion of the projection by causing an end portion of the projection to perform an ellipsoidal movement in response to a combination of two vibration modes generated in the vibrating body when an alternating driving voltage is applied to the electromechanical conversion device. The method includes forming the elastic body integrally with the projection and a bonding portion between the projection and the electromechanical conversion device by press working. To form a space and a spring portion having a spring characteristic in the projection at a position between the bonding portion between the projection and the electromechanical conversion device and the contact portion, the method further comprises forming a standing portion that connects the contact portion and the spring portion to each other and forming the spring portion such that the spring portion has a small thickness that is smaller than thicknesses of the contact portion, the standing portion, and the bonding portion between the projection and the electromechanical conversion device, or forming a standing portion between the bonding portion between the projection and the electromechanical conversion device and the contact portion so as to connect the bonding portion and the contact portion to each other and forming at least one hole in the standing portion. The step of forming the spring portion having the small thickness or the step of forming the at least one hole in the standing portion is performed when the elastic body is formed integrally with the projection and the bonding portion between the projection and the electromechanical conversion device by press working.

According to the present invention, a vibration actuator which has a stable spring stiffness and which can be easily manufactured and a method for manufacturing the vibration actuator are provided.

Further features of the present invention will become apparent from the following description of exemplary embodiments with reference to the attached drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1A and 1B illustrate the structure of a vibration actuator according to a first embodiment of the present invention.

FIG. 2 is a diagram illustrating a spring-like movement of a projection according to the first embodiment of the present invention.

FIGS. 3A and 3B illustrate the structure of a modification of the vibration actuator according to the first embodiment of the present invention.

FIGS. 4A and 4B illustrate the structure of a vibration actuator according to a second embodiment of the present invention.

FIG. 5 is a diagram illustrating a spring-like movement of a projection according to the second embodiment of the present invention.

FIGS. 6A and 6B illustrate the structure of a vibration actuator according to a third embodiment of the present invention.

FIG. 7 is a diagram illustrating the manner in which excess portions move according to the third embodiment.

FIGS. 8A and 8B illustrate the structure of a modification of the vibration actuator according to the third embodiment of the present invention.

FIG. 9 illustrates the structure of a vibration actuator according to a fourth embodiment of the present invention.

FIG. 10 is a diagram illustrating an example of multiple-degree-of-freedom driving according to the fourth embodiment of the present invention.

FIG. 11 illustrates the structure of a vibration actuator according to the related art.

FIGS. 12A and 12B illustrate bending modes of the vibration actuator.

FIG. 13 illustrates the structure of a vibration actuator according to the related art in which spaces are provided in a surface at the side opposite to projections.

DETAILED DESCRIPTION OF THE EMBODIMENTS

The structure according to embodiments of the present invention will now be described. The structure includes an elastic body on which at least one projection is formed and a vibrating body having an electromechanical conversion device. A driven member that is in contact with a contact portion of the projection is driven by an ellipsoidal movement of an end portion of the projection. The ellipsoidal movement is generated in response to a combination of two vibration modes generated in the vibrating body when an alternating driving voltage is applied to the electromechanical conversion device. In vibration actuators according to the embodiments, the elastic body is formed integrally with the projection and a bonding portion between the projection and the electromechanical conversion device by press working. Therefore, variations due to individual differences are small and stable performance can be achieved. In addition, the vibration actuators can be easily manufactured since the number of manufacturing steps is small. Therefore, the costs can be reduced. The projection is provided with a spring portion that causes the projection to exhibit a spring characteristic when the contact portion is pressed as a result of the contact with the driven member. The spring portion is disposed between the bonding portion between the projection and the electromechanical conversion device and the contact portion. A standing portion is formed so as to connect the contact portion and the spring portion to each other, the spring portion having a smaller thickness than those of the contact portion, the standing portion, and the bonding portion between the projection and the electromechanical conversion device. A space is provided between the contact portion, standing portion, spring portion and the electromechanical conversion device to which the projection is bonded. Alternatively, a standing portion is formed so as to connect the bonding portion between the projection and the electromechanical conversion device and the contact portion to each other, and at least one hole is formed in the standing portion. When the contact portion is pressed as a result of the contact with the driven member, the projection elastically deforms and exhibits a spring characteristic.

First Embodiment

The structure of a vibration actuator according to a first embodiment of the present invention will be described with reference to FIGS. 1A and 1B. FIG. 1A is a perspective view of the vibration actuator according to the present embodiment, and FIG. 1B is a sectional view of a single projection. As illustrated in FIG. 1A, the vibration actuator according to the present embodiment includes a vibrating body including projections 5 and an elastic body 6 and a driven member 8. As illustrated in FIG. 1B, each projection 5 includes a contact portion 1 between the elastic body 6 and the driven member 8, a spring portion 3 that reduces the vibration stiffness of the vibrating body in the direction in which a pressure is applied, and a standing portion 2 that connects the contact portion 1 and the spring portion 3 to each other. The elastic body 6 includes bonding portions 4 between the projections 5 and an electromechanical conversion device 7.

The elastic body 6 is formed integrally with each projection 5, and a space 9 is provided between the electromechanical conversion device 7 and the contact portion 1 of each projection 5. In each projection 5, the thickness of the spring portion 3 is smaller than those of the contact portion 1, the standing portion 2, and the bonding portion 4 between the projection 5 and the electromechanical conversion device 7. In the present embodiment, the spring portion 3 may be formed together with the contact portion 1, the standing portion 2, and the bonding portion 4 between the projection 5 and the electromechanical conversion device 7 when the elastic body 6 is formed by press working. Alternatively, the spring portion 3 may be formed after the elastic body 6 is formed integrally with each projection 5 and the bonding portion 4 between the projection 5 and the electromechanical conversion device 7 by press working. More specifically, the contact portion 1, the standing portion 2, and the bonding portion 4 between the projection 5 and the electromechanical conversion device 7 are formed in advance by press working. Then, the spring portion 3 may be additionally formed by electric discharge machining or the like such that the thickness of the spring portion 3 is smaller than those of the contact portion 1, the standing portion 2, and the bonding portion 4 between the projection 5 and the electromechanical conversion device 7. In the present embodiment, the spring portion 3 is formed by electric discharge machining. However, the spring portion 3 may instead be formed by etching or cutting.

In the above-described structure, when a force is applied to the contact portion 1, the spring portion 3, which is thinner than the contact portion 1, the standing portion 2, and the bonding portion 4 between the projection 5 and the electromechanical conversion device 7, functions as a diaphragm, as illustrated in FIG. 2. Accordingly, each projection 5 elastically deforms and exhibits a spring characteristic. As illustrated in FIGS. 3A and 3B, each projection may have a two-step structure. In this case, the distance between the spring portion 3 and the electromechanical conversion device 7 is increased. As a result, an adhesive used to attach the elastic body 6 to the electromechanical conversion device 7 does not easily adhere to the spring portion 3.

Second Embodiment

The structure of a vibration actuator according to a second embodiment of the present invention will be described with reference to FIGS. 4A and 4B. FIG. 4A is a perspective view of the vibration actuator according to the present embodiment, and FIG. 4B is a sectional view of a single projection. As illustrated in FIG. 4A, the vibration actuator according to the present embodiment includes a vibrating body including projections 5, an elastic body 6, and a plurality of holes 10 formed in the elastic body 6 and a driven member 8. As illustrated in FIG. 4B, each projection 5 includes a contact portion 1 between the elastic body 6 and the driven member 8, a standing portion 2 that connects the contact portion 1 and an electromechanical conversion device 7 to each other, and the holes 10 formed in the standing portion 2. Although four holes 10 are formed in the present embodiment, the number of holes is not limited as long as the number is 1 or more. The shape of the holes 10 may be circular, oblong circular, or an arc shape that extends along the shape of each projection 5. The elastic body 6 includes bonding portions 4 between the projections 5 and an electromechanical conversion device 7.

In the present embodiment, the holes 10 may be formed together with the contact portion 1, the standing portion 2, and the bonding portion 4 between the projection 5 and the electromechanical conversion device 7 when the elastic body 6 is formed by press working. Alternatively, the holes 10 may be formed by electric discharge machining or the like after the contact portion 1, the standing portion 2, and the bonding portion 4 between the projection 5 and the electromechanical conversion device 7 are formed by press working. In the present embodiment, the holes 10 are formed by electric discharge machining. However, the holes 10 may instead be formed by etching or cutting. In the above-described structure, when a force is applied to the contact portion 1, portions around the holes 10 elastically deform and exhibit a spring characteristic, as illustrated in FIG. 5. This is because the portions around the holes 10 have a lower stiffness than those of the contact portion 1, the standing portion 2, and the bonding portion 4 between the projection 5 and the electromechanical conversion device 7.

Third Embodiment

The structure of a vibration actuator according to a third embodiment of the present invention will be described with reference to FIGS. 6A and 6B. FIG. 6A is a perspective view of the vibration actuator according to the present embodiment, and FIG. 6B is a sectional view of a single projection. Referring to FIG. 6A, the vibration actuator includes a vibrating body including projections 5 and an elastic body 6 and a driven member 8. The vibrating body is provided with elongate holes 11 that receive excess portions generated during press working. As illustrated in FIG. 6B, in the vibration actuator according to the present embodiment, each projection 5 includes a contact portion 1 between the elastic body 6 and the driven member 8, a spring portion 3 that reduces the vibration stiffness of the vibrating body in the direction in which a pressure is applied, and a standing portion 2 that connects the contact portion 1 and the spring portion 3 to each other. The elastic body 6 includes bonding portions 4 between the projections 5 and an electromechanical conversion device 7. The elastic body 6 is formed integrally with each projection 5, and a space 9 is provided between the electromechanical conversion device 7 and the contact portion 1 of each projection 5. In each projection 5, the thickness of the spring portion 3 is smaller than those of the contact portion 1, the standing portion 2, and the bonding portion 4 between the projection 5 and the electromechanical conversion device 7.

The elongate holes 11 are formed in an area surrounding each projection 5 before the projection 5 is formed. Accordingly, as illustrated in FIG. 7, excess portions generated when each projection 5 is formed by press working are received by the elongate holes 11. Therefore, the contact portion 1, the standing portion 2, the spring portion 3, and the bonding portion 4 between the projection 5 and the electromechanical conversion device 7 can be formed integrally with each other by press working such that the thickness of the spring portion 3 is smaller than that in the case where the elongate holes 11 are not formed. Since the spring portion 3 is thinner than the contact portion 1, the standing portion 2, and the bonding portion 4 between the projection 5 and the electromechanical conversion device 7, the spring portion 3 functions as a diaphragm when a force is applied to the contact portion 1. As illustrated in FIGS. 8A and 8B, each projection may have a two-step structure. In this case, the distance between the spring portion 3 and the electromechanical conversion device 7 is increased. As a result, an adhesive used to attach the elastic body 6 to the electromechanical conversion device 7 does not easily adhere to the spring portion 3.

Forth Embodiment

The structure of a vibration actuator according to a forth embodiment of the present invention will be described with reference to FIG. 9. As illustrated in FIG. 9, the vibration actuator according to the present embodiment includes a vibrating body including a projection 5 and an elastic body 6 and a driven member 8. The spring structure is similar to that in the first embodiment. In the present embodiment, a single projection 5 is provided. Since the number of projections 5 is one, the area necessary to arrange the projection 5 is small. Accordingly, the size of the vibration actuator can be reduced. In addition, since the number of projections 5 is one, a multiple degree-of-freedom driving mechanism illustrated in FIG. 10, for example, can be achieved.

The multiple degree-of-freedom driving apparatus illustrated in FIG. 10 includes a pair of vibration actuators 12 and 13 according to the present embodiment. The vibration actuators 12 and 13 drive a moving body 14 that retains a driven member 15, such as a CCD, in X and Y directions. The vibration actuators 12 and 13 are arranged such that projections thereof are in pressure contact with a corner portion of the moving body 14 at the same position so as to sandwich the moving body 14 in the thickness direction. The vibration actuator 12 applies a driving force in the X direction to the moving body 14, and the vibration actuator 13 applies a driving force in the Y direction to the moving body 14. The moving body 14 is guided in the X direction by an X-direction guiding mechanism (not shown) and in the Y direction by a Y-direction guiding mechanism (not shown).

While the present invention has been described with reference to exemplary embodiments, it is to be understood that the invention is not limited to the disclosed exemplary embodiments. The scope of the following claims is to be accorded the broadest interpretation so as to encompass all such modifications and equivalent structures and functions. 

What is claimed is:
 1. A method for manufacturing a vibrating body relatively moving a driven member, the method comprising: forming a projection from part of an elastic body; and bonding a bonding portion of the elastic body to an electromechanical conversion device, wherein the projection comprises a contact portion contacting the driven member, a standing portion between the contact portion and the bonding portion, and a spring portion between the contact portion and the standing portion, wherein the standing portion is not bonded to the electromechanical conversion device, wherein the spring portion has an inner perimeter, wherein a space surrounded by the standing portion and the inner perimeter of the spring portion is provided between the contact portion and the electromechanical conversion device, and wherein the spring portion allows the contact portion to move toward the electromechanical conversion device and toward the space.
 2. The method according to claim 1, wherein the standing portion has a ring shape.
 3. The method according to claim 1, wherein the ring shape is a circle.
 4. The method according to claim 1, wherein the elastic body and the electromechanical conversion device are bonded via an adhesive.
 5. The method according to claim 1, wherein a degree of angle of the standing portion with respect to the electromechanical conversion device is larger than a degree of angle of the spring portion with respect to the electromechanical conversion device.
 6. The method according to claim 1, wherein the projection comprises the contact portion, a first standing portion as the standing portion, the spring portion, and a second standing portion between the contact portion and the spring portion.
 7. The method according to claim 6, wherein the inner perimeter of the spring portion forms an opening that is configured to allow at least part of the second standing portion to pass through the opening when the contact portion moves toward the electromechanical conversion device and toward the space.
 8. The method according to claim 1, wherein the spring portion urges the contact portion away from the electromechanical conversion device after the contact portion moves toward the electromechanical conversion device and toward the space.
 9. The method according to claim 1, wherein the spring portion has a stiffer spring function than the contact portion.
 10. A method for manufacturing a vibrating body relatively moving a driven member, the method comprising: forming at least a part of an elastic body into a projection; and bonding a bonding portion of the elastic body to an electromechanical conversion device, wherein the projection comprises a contact portion contacting the driven member, a spring portion between the contact portion and the bonding portion, and a standing portion, wherein the standing portion is not bonded to the electromechanical conversion device, wherein the spring portion has an inner perimeter, wherein a space surrounded by the standing portion and the inner perimeter of the spring portion is provided between the contact portion and the electromechanical conversion device, and wherein the spring portion allows the contact portion to move toward the electromechanical conversion device and toward the space.
 11. The method according to claim 10, wherein the spring portion is formed after the standing portion is formed.
 12. The method according to claim 10, wherein the spring portion has a ring shape.
 13. The method according to claim 10, wherein the elastic body comprises a plurality of the projections.
 14. The method according to claim 10, wherein the elastic body has a planar shape.
 15. The method according to claim 14, wherein the elastic body has a substantially rectangular planar shape.
 16. The method according to claim 10, wherein the spring portion and the electromechanical conversion device face each other.
 17. The method according to claim 16, wherein the projection is protruded from a first surface of the elastic body by press working, wherein the electromechanical conversion device is bonded to a second surface of the elastic body on a side opposite to the first surface, and wherein a distance between the spring portion and the electromechanical conversion device is larger than a distance between the first surface of the elastic body and the electromechanical conversion device.
 18. The method according to claim 16, wherein the bonding portion and the electromechanical conversion device are attached with an adhesive, and wherein the spring portion and the electromechanical conversion device face each other through the adhesive.
 19. The method according to claim 10, wherein the bonding portion comprises a portion having a thickness larger than a thickness of the spring portion.
 20. The method according to claim 10, wherein a hole is formed in the standing portion.
 21. The method according to claim 10, wherein the standing portion has a ring shape.
 22. The method according to claim 10, wherein the elastic body and the electromechanical conversion device are bonded via an adhesive.
 23. The method according to claim 10, wherein a degree of angle of the standing portion with respect to the electromechanical conversion device is larger than a degree of angle of the spring portion with respect to the electromechanical conversion device.
 24. The method according to claim 10, wherein the spring portion urges the contact portion away from the electromechanical conversion device after the contact portion moves toward the electromechanical conversion device and toward the space.
 25. The method according to claim 10, wherein the spring portion has a stiffer spring function than the contact portion.
 26. The method according to claim 10, wherein the projection comprises the contact portion, a first standing portion as the standing portion, the spring portion, and a second standing portion between the contact portion and the spring portion.
 27. The method according to claim 26, wherein the inner perimeter of the spring portion forms an opening that is configured to allow at least part of the second standing portion to pass through the opening when the contact portion moves toward the electromechanical conversion device and toward the space.
 28. A method for manufacturing a vibrating body relatively moving a driven member, the method comprising: forming a projection on an elastic body; and bonding a bonding portion of the elastic body to an electromechanical conversion device, wherein the projection comprises a contact portion contacting the driven member, a standing portion between the contact portion and the bonding portion, and a spring portion between the contact portion and the standing portion, wherein the standing portion is not bonded to the electromechanical conversion device, wherein the spring portion has an inner perimeter, wherein a space surrounded by the standing portion and the inner perimeter of the spring portion is provided between the contact portion and the electromechanical conversion device, wherein the spring portion allows the contact portion to move toward the electromechanical conversion device and toward the space, and wherein the forming the projection comprises: forming the standing portion and the spring portion by press working the elastic body.
 29. A method for manufacturing a vibrating body relatively moving a driven member, the method comprising: press working an elastic body to form a projection; and bonding a bonding portion of the elastic body to an electromechanical conversion device, wherein the projection comprises a contact portion contacting the driven member, a spring portion between the contact portion and the bonding portion, and a standing portion, wherein the standing portion is not bonded to the electromechanical conversion device, wherein the spring portion has an inner perimeter, wherein a space surrounded by the standing portion and the inner perimeter of the spring portion is provided between the contact portion and the electromechanical conversion device, and wherein the spring portion allows the contact portion to move toward the electromechanical conversion device and toward the space. 